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Ted:

Sounds like your alternator system is wired incorrectly.

Chase down the wiring associated with that switch. It should be in the field
circuit and not the main alternator output. The field should only require a
few Amps at most and should not result in a hot switch (unless it's some
sort of a micro-mini switch). It's possible that, due to misunderstanding
the function of the Alternator switch by who ever wired the airplane, it may
have been wired into the alternator output circuit. This circuit could see
peak currents of anywhere between 30 to 90 amps, depending on the
alternator, and is certainly capable of frying most of the switches commonly
used for this function.

The Alternator field circuit should provide 12 volts, at relatively low
amperage, via the switch and a breaker to the field circuit. The alternator
output should be wired straight to an appropriately sized (additional)
breaker and then directly to the main 12 volt bus.

Dan Schaefer

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Please send your photos and drawings to marvkaye@olsusa.com.
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